Elongate strip forming a toy building block base

ABSTRACT

A toy building block base comprises a flexible elongate body strip having a first major surface along a length of the strip that includes either an array of projections extending from the first major surface or an array of recesses set into the first major surface. The projections or recesses form a mating arrangement for co-operant toy building blocks. An opposite, second major surface has a shallow flat-bottomed longitudinal recess with a longitudinal adhesive layer by which the body strip can be attached to a support surface. The body strip includes no more than four projections or recesses across its width and has a length of at least 200 mm. The entire body strip is made from a homogenous flexible plastics material with a durometer value of between 35 and 80 according to the ASTM D2240 standard&#39;s type A durometer scale.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from United Kingdom patent applicationnumber 1619927.5 filed on 24 Nov. 2016 and from South Africanprovisional patent application number 2017/04276 filed on 23 Jun. 2017,both of which are incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates to an elongate strip forming a toy building blockbase and, more particularly, one that is compatible with existingsubstantially rigid toy building blocks.

Existing toy building blocks may include many variants but typicallyinclude at least basic building blocks that are of rectangularparallelepiped shape with multiple projections extending from onesurface that could be regarded as the male mating surface and anopposite female mating surface. The male mating surface typically formsa top surface in use, and the female mating surface a bottom surface sothat the blocks can be frictionally engaged or clipped together withcompatible building blocks to form structures of a chosen size andshape.

As a general rule, two rows of squat projections or accommodatingrecesses are provided across the width on a surface of a standard fullwidth building block whilst a single row of squat projections oraccommodating recesses is provided on the surface of a standard halfwidth building block. The lengths of a standard full width buildingblock and a standard half width building block generally vary from oneto eight squat projections or accommodating recesses in length and up tosixteen that is the longest of which applicant is aware. Numerousspecial external shapes of building blocks are provided to createreplica people, figures, characters and structures but all of them have,as a general rule, cooperating projections and recesses to enable theirtemporary interconnection with the basic toy building blocks.

BACKGROUND TO THE INVENTION

Typically the toy building block projections are squat approximatelycylindrical projections arranged in aligned rows extending along alength of the building block and the recesses are formed by a spacebetween side and end walls of a hollow block and one or more surfaces oflocking formations such as cylindrical formations extending from aninside of a top wall of the block to a bottom surface plane of theblock. The squat projections are, in an operative condition, engaged bythe inner surface of the sidewalls and any adjacent end walls and asurface of the locking formations. The sidewalls and end walls are,other than for specialist building blocks, smooth.

Probably the most common toy building block range of this generalnature, as far as applicant is aware, is that sold under the trade nameLEGO® which is a registered trademark of LEGO JURIS A/S of Denmark.However, other compatible toy building blocks are available such as MEGABLOKS® a trade mark of MEGA BLOK INC of Canada (working with MATTEL® andFISHER PRICE®) and KRE-O® construction blocks marketed by HASBRO® ofKorea.

It should be noted that the scope of this invention is not to beinterpreted as being limited in any way to use in conjunction with anyparticular range of toy building blocks and the bases of this inventioncould be used with any of the above or other types of toy buildingblocks of the same general nature, or even as a part of a custom toybuilding block set.

Prior art toy building block sets do have a facility for buildingreplica people, figures, characters and structures in relation to eachother in the form of a separate base sheet having formations thereon forreceiving building blocks in frictional or clipping relationshiprelative to the base sheet. These base sheets are of standard sizes andthe sizes of base sheets to be used are limited in number and must beselected or acquired according to the purpose.

Also, there are available on the market, square 10 inch (254 mm) by 10inch (254 mm) adhesive “LEGO® compatible tiles” that carry on theirobverse surface an array of formations suitable for receiving toybuilding blocks of the general type outlined above so that an entirestructure can be built on one or a plurality of juxtaposed alignedtiles. The tiles carry multiple projections arranged so that edge toedge location of the tiles results in a continuous series of theformations being created on the surface at the joints between tiles overa surface to which the tiles are adhered by means of an adhesive withthe outer edges in alignment. The adhesive is pressure sensitive andselected so that tiles may be releasably adhesively secured to anysuitable support surface and can be used for supporting replica people,characters and structures with the tiles being stuck, for example, on awindow, wall, article of furniture, appliance surface or a computersurface, simply by way of example.

MEGA BLOK INC® also provide a base that consists of a number of coplanarsections that are hingedly attached to each other so that a compositeflat base of different peripheral shapes can be created.

The versatility of toy building blocks of the general nature outlinedabove has proved to be exceptionally successful. However, these priorart types of bases are restrictive on certain types of creations thatmay be applied thereto in particular circumstances.

From the perspective of published prior art, EP 0621062 A2 toMesserschmitt describes a flexible sheet-like base that can followvarious contours. However, it does not envisage contours that may twistand turn and would be unsuitable for such applications.

U.S. Pat. No. 9,480,931 to Samo & Elliott describes a variety ofdifferent bases both rigid and flexible that have embedded therein atleast one elongate member embedded within the base and formed of adifferent material than that of which the base is made.

DE202013104194 to Sailer describes a floor covering that is not designedto follow any contour other than a flat floor and cannot thereforefollow twists and turns.

EP 3005894 to Capboytrading describes a cap having a peak and optionallya display plate on the cap having an array of multiple cylindricalprojections to which toy building blocks can be attached in the mannerindicated above. There is no suggestion that such a base could follow acontour that twists and turns.

The preceding discussion of the background to the invention is intendedonly to facilitate an understanding of the present invention. It shouldbe appreciated that the discussion is not an acknowledgment or admissionthat any of the material referred to was part of the common generalknowledge in the art as at the priority date of the application.

SUMMARY OF THE INVENTION

In accordance with a first aspect of this invention there is provided atoy building block base comprising a flexible elongate body strip havinga first major surface along a length of the strip that includes eitheran array of projections extending from the first major surface or anarray of recesses set into the first major surface, the projections orrecesses forming a mating arrangement for co-operant toy buildingblocks, the body strip having an opposite, second major surface that iseither flat or has at least one shallow flat-bottomed longitudinalrecess in either case with a longitudinal adhesive layer by which thebody strip can be attached to a support surface, wherein the body stripincludes no more than four projections or recesses across its width andhas a length of at least 200 mm, the entire body strip being made from ahomogenous flexible material with a durometer value of between 35 and 80according to the ASTM D2240 standard's type A durometer scale.

Further features provide for the body strip to have a width of between12 mm and 40 mm and to include two, three or four projections orrecesses across its width, preferably only two projections or recesses;and for the body strip to have a thickness defined between the firstmajor surface and second major surface of between 1 mm and 6 mm,preferably between 2.5 mm and 4.4 mm.

Further features provide for adhesive layer to be a pre-formed adhesivelayer applied to the toy building block base, preferably in anaccommodating shallow flat-bottomed longitudinal recess that receives amajor part of the thickness of the pre-formed adhesive layer. Thepre-formed adhesive layer may be a double sided adhesive polyurethanestrip and may include a removable cover strip on an exposed face pendinginitial use; and may be of a type that is reusable to permit the toybuilding block base to be peeled off a surface to which it is stuck andthen be stuck onto another surface in reusable manner. In the event thatthe body strip has a shallow flat-bottomed longitudinal recess, theadhesive layer may have a thickness of from 0.4 mm to 0.8 mm, and thelongitudinal recess may have a depth such that an exposed face of theadhesive layer is slightly proud of edges of the elongate body strip.

The toy block building base may have a length within the range of from200 mm to 3,000 mm, and preferably from 500 mm to 2,500 mm; and may bemade as an extrusion of indefinite length that is severed into selectedlengths.

Further features provide for the width of the toy building block base tobe selected to be the same as that of standard toy building blocks inassociation with which it is intended to be used; and for the durometervalue of the flexible material to be from 45 to 65 with preferred valuesbeing from 50 to 60. The toy building block base may be severable bycutting with a cutting instrument such as a pair of household scissors.

In the case of the body strip including an array of regularly spacedrecesses set into the first major surface, each recess may be formed bymultiple surface zones configured to engage portions of an outerperipheral surface of a projection of a toy building block receivedtherein discontinuously around the peripheral surface of the projection.

In the case of the body strip including an array of regularly spacedprojections extending from the first major surface, each projection mayhave a diameter that is slightly larger than a corresponding recess in acooperating toy block such that the projection deforms upon being urgedinto a corresponding recess to create frictional interference betweenthe projection and the cooperating toy block; for the projections to becylindrical projections; and for each projection to have a flat top anda chamfered or rounded edge between its cylindrical sidewall and itsflat top to guide the projection into the corresponding recess. In oneexample, the projections have an effective outer diameter of 4.95 mm(+/−0.5 mm), a 0.5 mm radius on the chamfered or rounded edge, and aheight of 1.8 mm, and are configured to cooperate with toy buildingblocks that have recesses with a diameter of 4.8 mm.

Further features provide for the first major surface of the body stripto include guide lines that assist a user in cutting the body strip witha cutting instrument such as a pair of scissors. The guide lines mayinclude a set of parallel transverse guide lines that extend at leastpartway across the width of the body strip at regular spaced intervalsbetween adjacent sets of projections or recesses to assist a user incutting across the width of the body strip at right angles to the lengthof the strip. The regular spaced intervals may be between every adjacentprojection along the length of the body strip. The guide lines may alsoinclude one or more longitudinal guide lines that extend between rows ofprojections or recesses along the length of the body strip to assist auser in cutting along the length of the body strip.

The guide lines may be formed by grooves in the first major surface ofthe body strip, and each guide line may include a set of alignedgrooves. Each individual groove in the set of grooves may be consistentwith one projection or recess so that an ease of cutting with a cuttinginstrument such as a pair of scissors changes each time a user cuts adistance associated with one projection or recess.

The toy building block base may be marketed in loose form from bulkpacks thereof; individually wrapped form; or in the form of rolls orlooped coils thereof of predetermined lengths.

The material from which the toy building block base is made preferablyhas little plastic memory, and most preferably has substantially noplastic memory. The toy building block base may be made from a plasticsmaterial, and the plastics material may be selected from thermoplasticrubber (TPR) or from polymeric organic silicon compounds often referredto as silicones. These plastics materials may be sufficiently deformableto bend but rigid enough to support toy building blocks byinter-engagement of the projections or recesses of the toy buildingblock base with co-operating recesses or projections of a generallyrigid toy building block.

Alternatively, the material could be a paper pulp product that is in aflexible matrix that exhibits appropriate properties of flexibility. Apulverized or powdered cork product that is in a flexible matrix couldalso be used.

As a further alternative, the toy building block base may be composed ofa multitude of short lengths of building block base carried by aflexible tape rendering the toy building block base flexible as definedabove.

In accordance with a second aspect of this invention there is provided atoy building block set comprising multiple toy building blocks and atleast one toy building block base, the toy building blocks each having afirst major flat surface with an array of projections forming a malemating surface and an array of recesses forming a female mating surface,with the recesses extending inwards from a second opposite major surfaceplane spaced from the first major flat surface by a distance defining aheight of the toy building block, wherein one toy building block can befrictionally engaged together by at least some of the projections of amale mating surface engaging in recesses in a female mating surface of acompatible building block to form composite structures of a chosen sizeand shape, wherein the toy building block base includes a flexibleelongate body strip having a first major surface along a length of thestrip that includes either an array of projections extending from thefirst major surface or an array of recesses set into the first majorsurface, the projections or recesses of the toy building block baseforming a mating arrangement for the toy building blocks, the body striphaving an opposite, second major surface that is either flat or has atleast one shallow flat-bottomed longitudinal recess in either case witha longitudinal adhesive layer by which the body strip can be attached toa support surface, wherein the body strip includes no more than fourprojections or recesses across its width and has a length of at least200 mm, the entire body strip being made from a homogenous flexiblematerial with a durometer value of between 35 and 80 according to theASTM D2240 standard's type A durometer scale.

Further features of the second aspect of the invention provide for atleast some of the toy building blocks to have a standard width and thewidth of the toy building block base to be the same as the standardwidth of the toy building blocks; and for toy building blocks that areof the thinnest building block of the set thereof to have a standardheight and a thickness of the toy building block base to be the same asthat standard height. The toy building blocks may be substantiallyrigid.

In accordance with a third aspect of the invention there is provided amethod of manufacturing a toy building block base, the method comprisingextruding a plastics material into an elongate body strip using anextrusion die, the plastics material being selected to be flexible andhaving a durometer value once set of between 35 and 80 according to theASTM D2240 standard's type A durometer scale, roll forming the elongatebody strip by means of a roller mould that presses the elongate bodystrip to include either an array of projections or an array of recessesin a first major surface along the length of the body strip, andsevering the elongate body strip into selected lengths.

Further features provide for the method to include a step ofcontinuously applying an adhesive layer to an opposite, second majorsurface along the length of the body strip. The adhesive layer may beapplied as one surface of a double sided adhesive layer. The body stripmay include a shallow flat-bottomed longitudinal recess in the secondmajor surface formed by the extrusion die and the adhesive layer may belocated in the shallow flat-bottomed longitudinal recess. The adhesivelayer may be made of polyurethane. In the event of a flat-bottomedlongitudinal recess being present, it is preferably of a depth such thatan exposed face of the adhesive layer is slightly proud of edges of theelongate body strip of the toy building block base. The relevant surfaceof the elongate body strip may be treated with a solvent in order toprepare it for bonding to the adhesive and enhance the bond of theadhesive to the toy building block base to create a permanent bond. Onthe other hand, an exposed face of the adhesive layer may be coveredwith a cover strip pending initial use and the adhesive layer may bereusable in that it can be peeled off a surface to which it is stuck andthen be stuck onto another surface in reusable manner.

In accordance with a fourth aspect of this invention there is provided amethod of constructing a toy structure using a toy building block baseaccording to the first aspect, the method comprising attaching the toybuilding block base to a support surface at two or more zones along thelength thereof by contacting the adhesive layer of the toy buildingblock base to the support surface, the toy building block base beingunsupported between the two or more zones, and attaching a plurality ofco-operant toy building blocks to the toy building block base betweenthe zones in the unsupported areas so as to create a toy structuresupported by the toy building block base.

In accordance with a fifth aspect of this invention there is provided atoy building block base comprising an elongate strip of a flexibleplastic material having a length of at least 200 mm. The strip has (i) afirst major surface that includes an array of regularly spacedprojections extending above the first major surface for interconnectingthe strip with one or more co-operant toy building blocks, and (ii) asecond major surface on a side of the strip opposite from the firstmajor surface. An adhesive is provided on the second major surface forattaching the strip to a supporting surface.

In accordance with a sixth aspect of this invention there is provided atoy building block base comprising an elongate strip of a flexibleplastic material having a length of at least 200 mm. The strip has (i) afirst major surface that includes an array of regularly spaced recessesset into the first major surface for interconnecting the strip with oneor more co-operant toy building blocks, and (ii) a second major surfaceon a side of the strip opposite from the first major surface. Anadhesive is provided on the second major surface for attaching the stripto a supporting surface.

Further features of the fifth and sixth aspects provide that the stripmay have either two or four parallel rows of projections or recessesrunning along the length of the strip, and may be up to 2,000 mm inlength. The toy building block base may be severable, for example bycutting with household scissors or tearing by hand. In some embodimentsthe flexible plastic material from which the strip is made hassubstantially no plastic memory.

In order that the above and other features of the invention may be morefully understood various embodiments of the invention will now bedescribed, by way of example only, with reference to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is an isometric view of a length of toy block building baseaccording to an embodiment of the invention;

FIG. 2 is a detail view of the portion indicated as “A” on FIG. 1;

FIG. 3 is similar to FIG. 2 but from a lower perspective and showing aremovable cover strip of an adhesive layer that is partly removed;

FIG. 4 is a top view of a length of toy building block base according toan embodiment of the invention;

FIG. 5 is a detail view of a portion of toy building block baseindicated as “B” on FIG. 4;

FIG. 6 is a front view of the length of toy building block base of FIG.4;

FIG. 7 is a cross-section taken through a toy building block base alongline I-I in FIG. 6;

FIG. 8 is a detail view of the portion indicated as “C” on FIG. 6;

FIG. 9 is a front view of a length of toy building block base accordingto an embodiment of the invention having generally rigid toy buildingblocks attached thereto;

FIG. 10 is an isometric view from above of one form of standard heighttoy building block;

FIG. 11 is an isometric view from below of the same toy building blockillustrated in FIG. 10;

FIG. 12 is a top isometric view of a plate toy building block similar tothat illustrated in FIG. 10;

FIG. 13 is an underneath isometric view of the same plate toy buildingblock illustrated in FIG. 12;

FIG. 14 is an end view of a length of toy building block base accordingto an embodiment of the invention next to which a generally rigid platetoy building block building block has been located on a support surfaceso that the two can jointly support a transverse generally rigidbuilding block;

FIG. 15 is a three-dimensional view of a roll of the toy building blockbase according to an embodiment of the invention;

FIG. 16 is an isometric view of a length of looped coils of the toybuilding block base according to an embodiment of the invention;

FIG. 17 is a three dimensional view of a length of toy block base thatis curved in a generally sinusoidal shape and is attached to a supportsurface at two or more zones along its length;

FIG. 18 is an isometric view of a somewhat shorter length of toy blockbase that is attached to two separate support surfaces at its ends andis unsupported between its ends;

FIG. 19 is a top view of an embodiment of toy building block baseaccording to an embodiment of the invention having an array ofcomplementary recesses serving as a female mating surface;

FIG. 20 is a cross-section taken through the toy building block basetaken along line II to II in FIG. 19;

FIG. 21 is an isometric view of an alternative embodiment of a toy blockbase having an array of complementary recesses serving as a femalemating surface;

FIG. 22 is an isometric view of a variation of toy building block baseaccording to an embodiment of the invention having four rows ofcylindrical projections;

FIG. 23 is an isometric view of a variation of toy building block basewhich does not include any guide lines;

FIG. 24 is a front view of a length of toy building block base accordingto an embodiment of the invention in which living hinges are formedbetween sets of projections;

FIG. 25 is a front view of a construction of toy building block basecomposed of a multitude of short lengths of toy building block basecarried by a flexible tape;

FIG. 26 is an isometric view of a machine that includes an extrusion dieand a roller mould for manufacturing two lengths of toy building blockbase side-by-side;

FIG. 27 is a schematic side view of the machine of FIG. 26; and

FIG. 28 is an alternative machine that includes an extrusion die and aroller mould for manufacturing one length of toy building block basethat has four rows of cylindrical projections.

DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS

FIGS. 1 to 8 show one embodiment of a toy building block base (10)according to the invention. The toy building block base (10) is in theform of a flexible elongate body strip (12) having a first major surface(14) along a length of the strip with an array of projections (16)extending from the first major surface (14).

The toy building block base (10) is provided for use in association withgenerally rigid toy building blocks (50, 52) of which two variants areshown in FIGS. 10 to 13, or other co-operant blocks of special type,such as those sold under the trade name LEGO®. Such building blocks (50,52) have at least one flat surface (54), usually used as the topsurface, with multiple projections (56) forming a male mating surface,and an array of recesses (58) that form a female mating surface having asurface plane from which the recesses extend inwards and usually forminga bottom surface. Different toy building blocks (50, 52) can befrictionally engaged or clipped together with compatible building blocks(50, 52) with at least some of the multiple projections (56) engaging inat least partially overlapped female recesses (58) of another toybuilding block (50, 52) to form structures of a chosen size, shape andconfiguration.

Referring back to FIGS. 1 to 8, the first major surface (14) of the toybuilding block base (10) is an otherwise flat surface so that the arrayof projections (16) defines a male mating arrangement for co-operant toybuilding blocks (50, 52). In this embodiment the projections (16) areregularly spaced squat right circular cylindrical projections arrangedin adjacent aligned pairs in two parallel rows along the length of theflexible elongate body strip (12) so that the strip includes twoprojections (16) across its width. The flexible elongate body strip (12)has a width corresponding to the width of a single standard toy buildingblock (50, 52) which may, for example, be 15.8 mm. The invention is notlimited to this width, however, and the width may vary between 12 mm and40 mm with two, three or four projections across the width.

An opposite, second major surface (18) of the strip has, as illustratedin FIG. 3, a pressure sensitive adhesive (20) that is able to attach thetoy building block base (10) to a flat or contoured surface. Thepressure sensitive adhesive (20) is covered with a removable cover strip(22) on an exposed face of the adhesive (20) pending initial use. Thepressure sensitive adhesive (20) is preferably of a releasable type inorder to allow for repositioning of the toy building block base (24) ona supporting surface therefor. This may permit the toy building blockbase (10) to be peeled off a supporting surface to which it is stuck andthen stuck onto another surface in a reusable manner.

The adhesive (20) could be applied directly to the toy building blockbase (10), but is preferably constituted by one side of a preformedadhesive layer (26) applied to the toy building block base (10) duringor after manufacture, as shown in FIG. 7. The second major surface (18)of the toy building block base (10) may be flat in which instance theadhesive (20) only, or the preformed adhesive layer (26), may be appliedto the flat second major surface (18). In the illustrated embodiment,however, the adhesive layer (26) is located in a shallow flat-bottomedlongitudinal recess (28) in the second major surface (18) of the toybuilding block base (10). While only one shallow flat-bottomedlongitudinal recess (28) is illustrated in these embodiments, it will beappreciated that two or more shallow flat-bottomed longitudinal recessescould extend side-by-side along the length of the body strip, or anumber of separate recesses could be formed with bridging portions thatextend at regular intervals along the length of the body strip.

The adhesive used to attach the adhesive layer (26) to the toy buildingblock base may be the same as that intended to attach the toy buildingblock base to a supporting surface and it may be applied before theadhesive layer (26) is applied to the toy building block base (10) as itis manufactured. In one embodiment, the adhesive layer (26) is appliedas one side of a double sided adhesive polyurethane strip that islocated in the shallow flat-bottomed longitudinal recess (28), the depthof which is such that the flat-bottomed longitudinal recess (28)receives a major portion of the thickness of the adhesive layer (26) andan exposed face (30) of the adhesive layer is slightly proud of theedges (32) of the elongate body strip (12) extending along each side ofthe shallow flat-bottomed longitudinal recess (28), as shown in FIG. 7.The adhesive layer (26) may have a thickness of between 0.4 mm and 0.8mm with the depth of the flat-bottomed longitudinal recess (28) beingslightly less than the thickness of the adhesive layer (26), such as 0.3mm to 0.7 mm. The adhesive layer (26) and flat-bottomed longitudinalrecess (28) are also narrower than the width of the body strip (12) sothat the edges (32) form shoulders. The shoulders assist a user to prisethe toy building block base (10) off a surface to which it is attachedfrom the side using a finger to curl up the material of the body strip(12) along one side of the strip (12).

Each projection (16) may have a diameter that is slightly larger than acorresponding recess (58) in a cooperating toy block (50, 52) such thatthe projection (16) deforms upon being urged into a corresponding recess(58) to create frictional interference between the projection and thecooperating toy block in order to keep the toy block engaged to the toybuilding block base when it is adhered to an upright or overhead supportsurface. It is desirable to be able to support not just one block, butan entire block assembly created from interconnected blocks. In thisembodiment the projections (16) are cylindrical projections, with eachprojection having a flat top (60) and a rounded edge (62) between itscylindrical sidewall (64) and its flat top (60) to guide the projection(16) into the corresponding recess (58). In other embodiments, the edgecould be chamfered rather than rounded. Simply by way of example, in oneproduct design the projections have an effective outer diameter of 4.95mm (+/−0.5 mm), a 0.5 mm radius on the rounded edge, and a height of 1.8mm to provide a surface area around the outside of the projection thatcontributes to providing a surface friction force that helps keep theblock engaged with the toy building block base (10). These projections(16) are adapted to be received in a corresponding recess (58) of ablock (50, 52) having an effective diameter of 4.8 mm. That means thatin this instance the effective diameter of the projection is about 3%larger than the effective diameter of the recess, but a broader range ofbetween 2 and 5% is also envisaged.

In these embodiments of the invention the engaging projections (16) arecircular in plan, but in other embodiments they could be of a differentshape in plan view such as square or symmetrical cruciform shape. Whatis important is that the effective diameter of a projection is slightlylarger than the effective diameter of a recipient recess and there needsto be a “lead in” chamfered or rounded top edge to a projection to helpguide the projection into the a recipient recess.

The entire flexible elongate body strip (12) of the toy building blockbase (10) is made from a homogeneous flexible plastics material such asa thermoplastic rubber (TPR) or polymeric organic silicon compound oftenreferred to as silicones. The material preferably has little plasticmemory and most preferably no plastic memory. Such material issufficiently deformable to bend but rigid enough to support a suitablylarge assembly of toy building blocks (50, 52) by inter-engagement ofthe projections (16) of the toy building block base with co-operatingrecesses (58) of one or more generally rigid toy building blocks (50,52). The toy building block base (10) is also flexible so that it canflex to follow a three dimensional contour when attached to a supportingsurface or structure having a contour other than flat whilst retainingits ability to support multiple toy building blocks (50, 52) or othercompatible blocks of special shape. A durometer value of the flexibleplastics material of between 35 and 80 is a target range with apreferred value being from 45 to 65 and more preferably being from 50 to60, according to the ASTM (American Society for Testing and Materials)D2240 standard's type A durometer scale. These durometer values enablethe body strip (12) to be severable using a cutting instrument such as apair of household scissors. The contour may twist and turn to an extentcompatible with the positioning of any generally rigid toy buildingblocks (50, 52) that are to be attached to it.

Alternative materials that could be used for the flexible elongate bodystrip (12) include a paper pulp product that is in a flexible matrixthat exhibits appropriate properties of flexibility, or a pulverized orpowdered cork product that is in a flexible matrix.

The toy building block base can be made in selected lengths typicallywithin the range of from 200 mm to 3,000 mm, and preferably from 500 mmto 2,500 mm. In the event that the width of the toy building block baseis a known width of 15.8 mm, a 1 metre length would correspond to aratio of width to length of 1:63 for a length of approximately 1 metre;1:126 for a length of approximately 2 metres; and a ratio of 1:30 for alength of just under a half a metre.

As regards thickness, the toy building block base (10) has a thickness,being the distance between the first and second major surfaces (14, 18),that is at least to a large extent dependent on the material ofmanufacture and is preferably between 1 mm and 6 mm, and more preferablybetween 2.5 mm and 4.4 mm. The thickness is selected primarily such thatthe toy building block base (10) is sufficiently flexible so that it canflex to follow a three dimensional contour by bending and twisting whenattached to a supporting surface or structure having a contour otherthan a flat. The toy building block base must however retain its abilityto support co-operant toy building blocks and other co-operant blocks ofspecial shape by way of inter-engaging male and female mating surfaceswithout the risk that they become easily separated. The thickness is inexcess of the height of the cylindrical projections (16) above the flatsurface. It will be quite apparent that the thickness is also determinedby the sharpness of bend that is to be applied to the toy building blockbase whilst not distorting the arrangement of projections or recessesexcessively so that they retain their functionality.

The first major surface (14) of the flexible elongate body strip (12)may include guide lines (36) that assist a user in cutting the bodystrip with a cutting instrument such as a pair of scissors. The guidelines (36) are most clearly shown in FIG. 5 and include a set ofparallel transverse guide lines (38) that extend across the majority ofthe width of the body strip (12) at regular spaced intervals betweenadjacent sets of projections (16) to assist a user in cutting across thewidth of the body strip (12) at right angles to the length of the strip(12). In this embodiment the regular spaced intervals are between everyadjacent projection (16) along the length of the body strip (12) but theregular spaced intervals could be every two, three or four or more setsof projections (16). Each transverse guide line (38) is, in thisembodiment, formed by a set of two aligned grooves (40, 42) in the firstmajor surface (14) of the body strip (12), with each individual groove(40, 42) in the set of grooves (40, 42) being consistent with oneprojection (16) so that the ease of cutting with a cutting instrumentsuch as a pair of household scissors changes each time a user cuts adistance associated with one projection (16).

The guide lines (36) also include a longitudinal guide line (44) thatextends between the two rows of projections (16) along the length of thebody strip (12) to assist a user in cutting along the length of the bodystrip (12). In embodiments in which two, three or four projections (16)extend across the width of the body strip, longitudinal guide lines mayextend between each row of projections (16).

In other embodiments, the guide lines may be deeper and may optionallyeven render the material of the body strip (12) frangible along a guideline by tearing it. Although in FIG. 5 guide lines (36) are shownbetween every pair of projections (16), guide lines could be providedbetween any numbers of pairs of projections.

As shown in FIG. 9, the toy building block base (10) is configured to beused together with generally rigid toy building blocks (50) that mayform part of a set or may be sold separately. In either event,structures can be built in well-known manner that are supported, in thisinstance, on the toy building block base (10) of this invention.

Some building block sets with which the toy building block base (10) isto be used may have rather thin building blocks (52) as some of theircomponents that in some instances are referred to as plate buildingblocks (52). The toy building block base (10) may in such cases have athickness selected so that its first major surface (14) is at the sameheight as that of a thin plate building block (52) placed next to it ona common base (70) or other toy building block, as shown in FIG. 14. Astructure or assembly of building blocks including standard height toybuilding blocks (50) and optionally other building blocks can be made toextend partially onto the toy building block base (10) and partly onto ajuxtaposed plate building block (52), whilst remaining parallel to asupporting structure (70).

This possibility leads to one embodiment of the invention in the form ofa toy building block set including at least one toy building block base(10) according to this invention together with multiple generally rigidstandard or other existing toy building blocks (50, 52). The generallyrigid toy building blocks (50, 52) may be of various lengths anddifferent heights although the basic building blocks may have twodifferent heights for convenience of construction. Simply for the sakeof illustration and completeness of disclosure, FIGS. 10 and 11illustrate the top and bottom of a standard height of basic buildingblock (50) that has a first major flat surface (54) that can be regardedas a top surface with multiple cylindrical projections (56) forming amale mating surface compatible with those on the toy building block baseof this invention. Recesses (58) form a female mating surface on anopposite second major surface plane spaced from the first major surfacefrom which the projections extend by a distance defining a height of thestandard toy building block (50).

The arrangement is such that one generally rigid toy building block (50)can be frictionally engaged or clipped together with at least some othergenerally rigid building blocks (50, 52) with the cylindricalprojections of a male mating surface engaging in accommodating recesses(58) in the second major surface of a compatible building block (50, 52)to form composite structures of a chosen size and shape. The toybuilding block set includes at least one flexible toy building blockbase (10) as described above for optional use as and when required.

It will be quite apparent that the length of the toy building block base(10) may be considerable and will be chosen according to requirementsand according to intended use, as well as sales and promotionalstrategy. Typically shorter lengths of say 320 mm to 400 mm may beindividually packed in wrappers or blister packs whilst longer lengthsmay be rolled up and wrapped or packed in blister packs. A roll (72) ofstrip toy building block base is illustrated in FIG. 15 whilst a loopedcoil package (74) in the fashion of a skein is shown in FIG. 16, simplyby way of example. As indicated above, the toy building block base maybe made in many different discrete lengths.

The advantageous properties of toy building block bases according tothis invention cannot be practically realized without careful productdesign. The choice of material should be such that bending and flexingof the strip material forming the toy building block base does notsignificantly alter the positioning and tolerance of the projections orrecesses that are to engage with co-operant formations on co-operatingtoy building blocks to the extent that the building blocks cannot beproperly engaged. Also, it is important that positioning and toleranceof the projections or recesses remains substantially unchanged afterrepeated deformation of the projections or recesses.

As a result of the fact that the materials are typically flexible,elastic materials, the size and profile of the engaging projections orrecesses is key to providing the desired load bearing characteristics ofthe brick to toy building block base inter-engagement when the productis supporting toy building blocks on an upright support surface orhanging bricks from an overhead support surface.

As an example, a test may be performed to assess the ability for a blockto remain engaged with the toy building block base under the applicationof a force acting to pull the block apart from the toy building blockbase. In one such example, a toy building block base (10) having tworows of projections (16) across its width may be affixed to theunderside of an overhead horizontal plate. The projections (16) may beof the form described in some preceding exemplary embodiments, with aneffective outer diameter of 4.95 mm (+/−0.5 mm), a 0.5 mm radius on therounded edge, and a height of 1.8 mm, circular in plan. The block isattached to the toy building block base so as to engage with eight ofthe projections, each being received in a corresponding recess (58) ofthe block that has an effective diameter of 4.8 mm. The building blockcan be loaded with metallic weights, such that the weight force acts topull the block apart from its engagement with the toy building blockbase. In some embodiments, tested in this manner, the block may beloaded to a weight of 415 grams, and the engagement can support thisloading for over 30 seconds. In some embodiments, the inter-engagementof the block and the toy building block base, via eight projections, cansupport over 400 grams of weight, or at least over 300 grams, whentested in this manner.

FIG. 17 shows that the toy building block base (10) may be attached to asupport surface at a number of zones (76) along the length of the bodystrip (12) by contacting the adhesive layer (26) of the toy buildingblock base (10) to the support surface. The toy building block base (10)is unsupported between the two or more zones (76), and toy buildingblocks (50), or indeed an entire assembly of toy building blocks (50),may be attached to the toy building block base (10) between the zones(76) in the unsupported areas, so as to create a toy structure supportedby the toy building block base (10). FIG. 18 shows a differentarrangement where a relatively short length of toy building block base(10) is attached to two separate objects (78, 80) at zones (82) towardsits free ends, with a middle part of the toy building block base (10)being unsupported and carrying one or more toy building blocks (50).

Numerous variations of the toy building block bases fall within thescope of the invention. FIGS. 19 and 20 show a toy building block base(100) that includes a flexible elongate body strip (102) having a firstmajor surface (104) along the length of the strip (102) that includes anarray of recesses (106) set into the first major surface (104) forming afemale mating arrangement for co-operant toy building blocks (50, 52) orfor co-operating with the male mating arrangement of the toy buildingblock base (10) illustrated in FIGS. 1 to 8. Each recess (106) may beformed by multiple surface zones configured to engage portions of theouter periphery of a projection (16, 56) of a toy building block (50,52) or co-operant toy building block base (10) received thereindiscontinuously around the surface of the projection (16, 56). Thisversion of the toy building block base (100) may therefore be termed thefemale or receiver version. As with the male version, the female versionof the toy building block base (100) includes a shallow-bottomedlongitudinal recess (108) that receives an adhesive layer (110) whichincludes a removable cover strip (112). Using male and female versionsof toy building block base (10, 100) together leads to the possibilitiesof their use in a manner akin to hook and loop fastener, where adhesiveof the male version can be attached to one object, adhesive of thefemale version attached to a different object, and the two objectsreleasably held together by means of the cooperating projections (16)and recesses (106).

FIG. 21 shows an alternative arrangement of recesses (122) in adifferent female version of the toy building block base (120). Thefemale versions (100, 120) may also be useful in the event that it isdesired to build downwards from an overhead or elevated surface.

FIG. 22 shows another embodiment of a toy building block base (200) thathas four projections (202) across its width so that it has fourlongitudinally extending rows of projections (202) so that two standardtoy building blocks each having two rows of projections can beaccommodated across the width of the toy building block base (200) nextto each other or in any other way. There is, of course, no restrictionas to the orientation in which the co-operating building blocks can bearranged that is dictated by their geometric arrangement relative toeach other. Three elongate guide lines (204) are included between thefour rows of projections (204).

FIG. 23 shows another embodiment of a toy building block base (300)which is somewhat simpler and includes a simple flat bottom without alongitudinal recess. In this event an adhesive layer may be thinner anddirectly applied to the flat bottom. The toy building block base (300)is also devoid of any guide lines.

As an alternative to the use of the inherent flexibility of a singlethickness of the material from which the toy building block base ismade, and as shown in FIG. 24, the thickness of the material may bedecreased between selected pairs of adjacent projections. In theinstance illustrated in FIG. 24, decreased zones (400) are providedafter every four pairs of projections that would correspond to astandard toy building block having four pairs of projections. Thesezones of decreased thickness provide what is known as living hingesbetween the adjacent zones that each have four pairs of projections sothat greater flexibility is provided at the living hinges with limitedflexibility between adjacent living hinges. Of course, these zones ofdecreased thickness may simply be grooves that could, in addition, serveas cutting or tearing guide lines.

FIG. 25 illustrates a construction of toy building block base (500) inwhich a multitude of short lengths (502) of building block base arecarried by a flexible tape (504) rendering the toy building block basesufficiently flexible as described above.

FIGS. 26 and 27 illustrate a method of manufacturing a toy buildingblock base according to an embodiment of the invention. A plasticsmaterial that has the properties previously discussed above is extrudedby means of an extrusion die (601) into an extrusion (600). In thisembodiment, two extrusions (600) are formed side-by-side. The extrusions(600) form elongate body strips (602) that are then roll formed prior tothe plastics material hardening by using a roller mould (604) thatpresses the elongate body strips (602) to include either an array ofprojections (606) or an array of recesses (in the case of a femaleversion of the product) in a first major surface (608) of each bodystrip (602). In this example, the roller mould (604) has a pair oftracks (610) therein that form the mould for the projections or recessesof the body strips (602).

A polyurethane adhesive layer (612) is thereafter continuously appliedto an opposite, second major surface (614) along the length of each bodystrip (602) and pressed into place by a pair of rollers (616, 618) toform a toy building block base (603) of the type in FIGS. 1-8. The bodystrip (602) may include a shallow flat-bottomed longitudinal recess inthe second major surface (614) as previously described into which theadhesive layer (612) fits so that an exposed face of the adhesive layeris slightly proud (such as 0.1 mm to 0.5 mm proud) of the edges of theelongate body strip. The longitudinal recess is preferably formed by theextrusion die so that it is included in the extrusion (600). Prior tothe adhesive layer being applied, the flat-bottomed longitudinal recessin the second major surface (614) may be primed or treated with asolvent in order to prepare it for bonding to the adhesive and enhancethe bond of the adhesive to the body strip (602) to create a permanentbond. An exposed face of the adhesive layer (612) may be covered with acover strip pending initial use and the adhesive layer (612) may bereusable in that it can be peeled off a surface to which it is stuck andthen be stuck onto another surface in reusable manner.

As a final step, the continuously formed body strips (602) are then thensevered into selected lengths which are typically greater than 200 mmbut may be from 200 mm to 3,000 mm, and preferably from 500 mm to 2,500mm.

FIG. 28 is similar to FIG. 26 but shows a single, wider extrusion (700)that emerges from an extrusion die (701) and is rolled with a rollermould (704) into a body strip (702) that has four projections (706)across its width, and an adhesive layer (712) applied to form a toybuilding block base (703) of the type illustrated in FIG. 22.

There are numerous uses for the toy building block base according to theinvention as will be quite apparent to those skilled in the art. The toybuilding block base can be stuck onto any suitable surface such as thatof a wall, window, undulating surfaces such as the handlebars of abicycle or any three-dimensional shaped surface such as the outersurface of a motor vehicle, motorbike, and numerous other differentsurfaces. The surface can involve twisting, turning and bending to anextent permissible by the flexibility of the toy building block base andthe particular arrangement of rigid toy building blocks with which thetoy building block base is to be used. In all instances the toy buildingblock base can be used to create a bridge from one surface to another oreven a sinuous wave-like structure supported on only its trough sectionsas shown in FIG. 17 or suspended from its peak sections in the case ofan overhead support surface. The configuration of the accommodatingrecesses may vary widely. As regards manufacturing, another method ofmanufacturing the toy building block base is by press moulding orinjection moulding the relevant material.

Throughout the specification and claims unless the contents requiresotherwise the word ‘comprise’ or variations such as ‘comprises’ or‘comprising’ will be understood to imply the inclusion of a statedinteger or group of integers but not the exclusion of any other integeror group of integers.

The embodiments discussed herein are representative of preferredembodiments of the present invention and are provided for illustrativepurposes only. They are not intended to limit the scope of theinvention. Although specific configurations, structures, materials, etc.have been shown and described, such are not limiting. Modifications andvariations are contemplated within the scope of the invention.

1. A toy building block base comprising a flexible elongate body striphaving a first major surface along a length of the strip that includeseither an array of projections extending from the first major surface oran array of recesses set into the first major surface, the projectionsor recesses forming a mating arrangement for co-operant toy buildingblocks, the body strip having an opposite, second major surface that iseither flat or has at least one shallow flat-bottomed longitudinalrecess in either case with a longitudinal adhesive layer by which thebody strip can be attached to a support surface, wherein the body stripincludes no more than four projections or recesses across its width andhas a length of at least 200 mm, the entire body strip being made from ahomogenous flexible material with a durometer value of between 35 and 80according to the ASTM D2240 standard's type A durometer scale.
 2. A toybuilding block base as claimed in claim 1 in which the body strip has awidth of between 12 mm and 40 mm and has two, three or four projectionsor recesses across its width.
 3. A toy building block base as claimed inclaim 1 in which the body strip has a thickness defined between thefirst major surface and second major surface of between 1 mm and 6 mm.4. A toy building block base as claimed in claim 1 in which the secondmajor surface has a shallow flat-bottomed longitudinal recess and theadhesive layer is a pre-formed adhesive layer that is received in theshallow flat-bottomed longitudinal recess with a major portion of athickness of the pre-formed adhesive layer being received in theflat-bottomed longitudinal recess.
 5. A toy building block base asclaimed in claim 1 in which the adhesive layer is a double sidedadhesive polyurethane strip and is reusable to permit the toy buildingblock base to be peeled off a surface to which it is stuck and then bestuck onto another surface in a reusable manner.
 6. A toy building blockbase as claimed in claim 1 having a length of from 500 mm to 2,500 mm.7. A toy building block base as claimed in claim 1 in which thedurometer value of the flexible material is from 45 to 65 and the toybuilding block base is severable by cutting with a pair of householdscissors.
 8. A toy building block base as claimed in claim 1 whichincludes an array of projections extending from the first major surface,each projection having a diameter that is between 2 and 5 percent largerthan a corresponding recess in a cooperating toy block such that theprojection deforms upon being urged into a corresponding recess tocreate frictional interference between the projection and thecooperating toy block.
 9. A toy building block base as claimed in claim1 which includes an array of projections extending from the first majorsurface, each projection being cylindrical with a flat top and a roundedor chamfered edge between its cylindrical sidewall and its flat top toguide the projection into a corresponding recess in a cooperating toyblock.
 10. A toy building block base as claimed in claim 1 in whichguide lines are provided in the first major surface of the body strip toassist a user in cutting the body strip with a cutting instrument.
 11. Atoy building block base as claimed in claim 10 in which the guide linesinclude a set of parallel transverse guide lines that extend at leastpartway across the width of the body strip at regular spaced intervalsbetween adjacent sets of projections or recesses to assist a user incutting across the width of the body strip at right angles to the lengthof the strip.
 12. A toy building block base as claimed in claim 10 inwhich the guide lines include one or more longitudinal guide lines thatextend between rows of projections or recesses along the length of thebody strip to assist a user in cutting along the length of the bodystrip.
 13. A toy building block base as claimed in claim 10 in which theguide lines are formed by grooves in the first major surface of the bodystrip.
 14. A toy building block base as claimed in claim 13 in whicheach guide line includes a set of aligned grooves, with each individualgroove in the set of grooves consistent with one projection or recess sothat the ease of cutting with a cutting instrument changes each time auser cuts a distance associated with one projection or recess.
 15. A toybuilding block base as claimed in claim 1 wherein the homogenousflexible material is thermoplastic rubber (TPR) or is a polymericorganic silicon compound.
 16. A toy building block set comprisingmultiple toy building blocks and at least one toy building block base,the toy building blocks each having a first major flat surface with anarray of projections forming a male mating surface and an array ofrecesses forming a female mating surface, with the recesses extendinginwards from a second opposite major surface plane spaced from the firstmajor flat surface by a distance defining a height of the toy buildingblock, wherein one toy building block can be frictionally engagedtogether by at least some of the projections of a male mating surfaceengaging in recesses in a female mating surface of a compatible buildingblock to form composite structures of a chosen size and shape, whereinthe toy building block base includes a flexible elongate body striphaving a first major surface along a length of the strip that includeseither an array of projections extending from the first major surface oran array of recesses set into the first major surface, the projectionsor recesses of the toy building block base forming a mating arrangementfor the toy building blocks, the body strip having an opposite, secondmajor surface that is either flat or has at least one shallowflat-bottomed longitudinal recess in either case with a longitudinaladhesive layer by which the body strip can be attached to a supportsurface, wherein the body strip includes no more than four projectionsor recesses across its width and has a length of at least 200 mm, theentire body strip being made from a homogenous flexible material with adurometer value of between 35 and 80 according to the ASTM D2240standard's type A durometer scale.
 17. A toy building block set asclaimed in claim 16 in which at least some of the toy building blockshave a standard width and the width of the toy building block base isthe same as the standard width of the toy building blocks.
 18. A toybuilding block set as claimed in claim 16 in which toy building blocksthat are of the thinnest building block of the set thereof have astandard height and a thickness of the toy building block base is thesame as that standard height.
 19. A method of manufacturing a toybuilding block base, the method comprising extruding a plastics materialinto an elongate body strip using an extrusion die, the plasticsmaterial being selected to be flexible and having a durometer value onceset of between 35 and 80 according to the ASTM D2240 standard's type Adurometer scale, roll forming the elongate body strip by means of aroller mould that presses the elongate body strip to include either anarray of projections or an array of recesses in a first major surfacealong the length of the body strip, continuously applying an adhesivelayer to an opposite, second major surface along the length of the bodystrip, and severing the elongate body strip into selected lengths.
 20. Amethod of manufacturing a toy building block base as claimed in claim 19in which the extrusion die forms a shallow flat-bottomed longitudinalrecess in the elongate body strip and the adhesive layer is applied sothat it is located in the shallow flat-bottomed longitudinal recess, theshallow flat-bottomed longitudinal recess being of a depth that itreceives a major portion of a thickness of the adhesive layer.
 21. Amethod of constructing a toy structure using a toy building block baseas claimed in claim 1, the method comprising attaching the toy buildingblock base to a support surface at two or more zones along the lengththereof by contacting the adhesive layer of the toy building block baseto the support surface, the toy building block base being unsupportedbetween the two or more zones, and attaching a plurality of co-operanttoy building blocks to the toy building block base between the zones inthe unsupported areas so as to create a toy structure supported by thetoy building block base.
 22. A toy building block base as claimed inclaim 1, in which the body strip has only two projections or recessesacross its width.
 23. A toy building block base as claimed in claim 1 inwhich the body strip has a thickness defined between the first majorsurface and second major surface of between 2.5 mm and 4.4 mm.
 24. A toybuilding block base as claimed in claim 1 in which the adhesive layer isa pre-formed adhesive layer applied to the toy building block base andthe adhesive layer has a thickness of between 0.4 mm and 0.8 mm.
 25. Atoy building block base as claimed in claim 1 in which the width of thetoy building block base is selected to be the same as that of at leastsome of the co-operant toy building blocks in association with which itis intended to be used.
 26. A toy building block base as claimed inclaim 1 in which the durometer value of the flexible material is from 45to
 65. 27. A toy building block base as claimed in claims 9 in which theprojections have an effective outer diameter of 4.95 mm (+/−0.5 mm), a0.5 mm radius on the chamfered or rounded edge, and a height of 1.8 mm,and are configured to cooperate with toy building blocks that haverecesses with a diameter of 4.8 mm.
 28. A toy building block base asclaimed in claim 1 in which the homogenous flexible material hassubstantially no plastic memory.
 29. A toy building block base asclaimed in claim 5 in which the double sided adhesive polyurethane stripincludes a removable cover strip on an exposed face pending initial use.30. A toy building block base as claimed in claim 1 in which the bodystrip has a thickness defined between the first major surface and secondmajor surface that is selected to be the same as a correspondingthickness of a plate building block so that the first major surface isat the same height as that of a plate building block placed next to iton a common base or on another toy building block.